Mattress



M. MARsAcK 2,204,863

MATTRESS Filed Jan. 19, 1958 Patented June 18, 1940 UNITED vSTATES' ,PATENT OFFICE MATTRESS Application January 19, 1938, Serial No. 185,641

6 Claims. (CL75-351) The linvention relates to mattresses of the kind comprising an inner resilient core or spring asf sembly, and more particularly it relates to improvements in the construction of the covering material and in the means for securing the covering materialto the spring assembly and to the border boxing of a mattress.

An object of the invention is the provision of improvements in the construction and the means for securing the covering material to the resilient core or spring assembly whereby the covering material is compressed and strengthened adiacent the border of the mattress in a manner to maintain verticality of the edge boxing and to provide a mattress having a trim and substantially square edge.

Another object of the invention is the provision of an improved closed edge multi-plyv pad having its edges inturned to overlie the resilient core and secured to the adjacent edges of the core in a manner to prevent bunching of the pad material or shifting of the pad relative to the spring construction.

A still further object of the invention is the production of a mattress of the kind described which may be readily manufactured with'a maximum of machine work and a minimum of hand labor, thereby reducing themanufacturing cost, speeding up production, and permitting an increased factory output without increasingmanufacturing facilities.

Still another object of the invention is the production of a mattress in which the edge. boxing and the top and bottom covering materials are respectively pre-built prior to assembling the mattress whereby the hand work in the final construction or assembly of the mattress is substantially eliminated, and such as is required is all concealed, and consequently may be done without the care and nicety of detail required where the hand work is exposed, and mattresses so constructed will be substantially uniform in appearance.

Many other objects and advantages of the construction and methods of assembling herein shown and described will be obvious to those skilled in the art from the disclosure herein given;

To this end my invention consists in the novel construction, varrangement and combination of parts herein shown and described, and more particularly pointed outin the claims.

Referring now tothe drawing:

Fig. l is a perspective view of a portion of a mattress embodying the principles of the invention;

Fig. 2 is a sectional view along theline 2 2.

. Fig. l; and

Fig. 3 is a perspective view of a portion of the pad shown in Figs. l and 2. l

Referring now more particularly to the drawyw ing, a plurality of vertical coils I are connected' top and bottom, by marginal helicals ll and by intermediate helicals I2 to provide a unitary spring construction.

, The top and the bottom of the spring assembly#C are each covered by a pre-built pad comprising a J ply of filling material l 3 interposed between fabric plies li and I5. The edges of the pad are closed by stitches it connecting the margins of the pliesl ld and l5. In the preferred embodiment of the invention, a cover sheet l'l is connected with each" pad by lines of stitches i8 extending through the pad and tending to compress the adjacent filling material I3 to produce a multi-cushion effect in the completed mattress. Layers of lling mate rial E3 are positioned between the pad and cover sheet in the areas between the lines of stitchingl to increase the cushioning qualities and resiliency of the mattress. The lateral and longitudinal dimensions of the cover sheets l1 correspond ang, 25

proximately to the over-all dimensions of the mattress. The lateral and longitudinal dimensions of the pads are greater than the correspending dimensions of the mattress, and the cover sheet ll is connected with the pad preferably so that the pad projects equally on all sides beyond the cover sheet.

The edges of the spring assembly are enclosed by a pre-built boxing strip comprising an outer fabric ply lil, and a ply of filling material 253,3 interposed between fabric plies 2| and 22, all conl" nected by eyelets 24. The plies 2li, 2l, and 22 terminate adjacent the top and the bottom of the spring construction, and the ply I9 has a width substantially equal to thethickness of the come., pleted mattress.

The mattress is assembled by placing the boxing around the springl construction preferably with the upper edge of the ply i9 folded downwardly. The pad and attached cover sheet I1 are! placed on top of the spring construction and the unconnected border of the sheet turned back. The projecting portions of the pad are then folded inwardly so that the edges of the pad are in substantial alignment with the edges of the spring' construction. Since the folded portions overlap at the corners of the mattress, less filling material I3 is used at the corners of the pad in order that the mattress border may have the ,same

thickness at the corners that it has at the intermediate portions.

The inturned portions of the pad and also the portions of the pad over which the inturned portions project are compressed and connected by lacings 25 extending therethrough and through the adjacent border helicals Il and the edges of the boxing plies 20, 2l, and 22. The lacings 25 are drawn taut and the overlapping portions of the pad are compiessed as shown in Fig. 2, as the stitching proceeds. The resulting taut connection of the compressed portions of the pad prevents movement of the pad relative to the spring construction when the lacing is completed. Since the lacings 25 are eventually covered by the boxing ply I 9 and the cover sheet l'l, the attachment of the pad to the helicals and to the boxing can be done rapidly by hand and without undue attention to niceties of detail or the appearance of the edges of the pad since the laced and compressed borders of the pad are enclosed by ply i9 lling material 23 and cover sheet I?. The marginal edges of the cover sheet l1 and the adjacent edges of the boxing ply I9 are next brought together and covered by a tape 2E and connected by stitches 2l. The mattress is then turned over and a pad and attached cover sheet are positioned on the other side of the spring assembly. The mattress is completed by the same steps or operaw tions on theI inverted portion of the mattress, all in the same manner as described for the other side of the mattress. The folded and compressed edges of the pad covered with the filling material 29 as described give a trim square effect to the edge of the mattress and resist any tendency of the border of the mattress to sag under loads.

Thus, it will be seen that I have provided improvements in the construction and arrangement of covering materials for mattresses and also that I have provided improved means i or securing the covering materials to the spring construction and to the edge boxing.

Having thus described my invention, it is obvious that various immaterial modifications may be made in. the same Without departinCT from the spirit of my invention; hence I do not wish to be understood asv limiting myself to the exact form, construction, arrangement and combination of parts herein shown and described or uses mentioned.

Vtfhat I claim as new and desire to secure by Letters Patent is:

l. In a mattress of the kind described and in combination, a spring assembly, a covering for the spring assembly comprising two fabric sheets and an interposed layer of compressible filling material of substantially uniform thickness, means connecting the edges of the fabric sheets to provide a closed pad, a cover sheet for the pad, the longitudinal and lateral dimensions of the pad and cover sheet being greater than 'the corresponding dimensions of the spring construction, the edge portions of the pad being folded underneath the cover sheet, the marginal overlapping portions of the pad being compressed to substantially the saine thickness as the intermediate portion, a boxing strip consisting of outer and inner fabric sheets extending around the edge of the spring construction, tie members extending through the pad and connecting the inner marginal edges of said folded portions with the adjacent edges of the spring assembly and with the inner fabric sheet of said boxing strip, and means connecting the adjacent marginal edges of the cover sheet with the outer fabric sheet of said boxing strip.

2. In a mattress of the kind described and in combination, a spring assembly, a covering for the spring assembly comprising two fabric sheets and an interposed layer of compressible filling material of substantially uniform thickness, means connecting the edges of the fabric sheets to provide a closed pad, a cover sheet for the pad, the longitudinal and lateral dimensions of the pad and the cover sheet being greater than the corresponding dimensions of the spring construction, the edge portions of the pad being folded underneath the cover sheet, the marginal overlapping portions of the pad being compressed to substantially the same thickness as the intermediate portion, a boxing strip consisting of outer and inner fabric sheets extending around the edge of the spring construction, tie members extending through the pad and connecting the inner marginal edges of said folded portions with the adjacent edges of the spring assembly and with the inner fabric sheet of said boxing strip, filling material positioned between the cover sheet and the pad, and means connecting the adjacent marginal edges of the cover sheet and the outer fabric sheet of the boxing strip.

3. In a mattress of the kind described and in combination, a spring assembly, a covering for lthe spring assembly comprising two fabric sheets and an interposed layer of compressible filling material of substantially uniform thickness, means connecting the edges of the fabric sheets to provide a closed pad, a cover sheet for the pad, the longitudinal and lateral dimensions of the pad and the cover sheet being greater than the corresponding dimensions of the spring construction, the edge portions of the pad being folded underneath the cover sheet, the marginal overlapping portions of the pad being compressed to substantially the same thickness as the intermediate portion, a border boxing extending around the edges of the spring construction comprising an outer fabric ply of substantially the depth of the mattress, two inner fabric strips and an interposed layer of filling material of substantially the depth of the spring assembly, and means forming a. quilted connection of the boxing material, tie members extending through the pad and connecting the inner marginal edges of said folded portions with the adjacent edges of the spring assembly and with said inner fabric boxing strips, and means connecting the adjacent marginal edges of said cover sheet and outer boxing ply.

4. In a mattress of the kind described and in combination, a spring assembly, '1. covering for the spring assembly comprising two fabric sheets and an interposed layer of compressible filling material of substantially uniform thickness, means connecting the edges of the fabric sheets to provide a closed pad, a cover sheet for the pad, the longitudinal and lateral dimensions of the pad and the cover sheet being greater than the corresponding dimensions of the spring construction, the edge portions of the pad being folded underneath the cover sheet, the marginal overlapping portionsl of the pad being compressed to substantially the saine thickness as the intermediate portion, a border boxing extending around the edge of the spring construction comprising an outer fabric ply of substantially the depth of the mattress, two inner fabric strips and an interposed layer of filling material of substantially the depth of the spring assembly and means forming a quilted connection of the boxing material, tie members extending through the pad and connecting the inner marginal edges of the said folded portions with the adjacent edges of the spring assembly and with said boxing inner fabric strips, filling material positioned p between the cover sheet and the pad, and means connecting the adjacent marginal edges of saidl the kind described of a cover sheet, a pad of compressible material positioned on the assembly under the cover sheet and initially having lateral and longitudinal dimensions greater than the corresponding dimensions of said assembly and cover sheet, the marginal edges of the pad being folded underneath the cover sheet to provide a compressed double thickness overlying the spring assembly, a border boxing comprising a plurality of connected plies extending around the edges of the spring assembly, a line of lacings extending diagonally through the double thickness of the pad and connected with the spring assembly, said lacings extending through the inner ply of said boxing for maintaining said double thicknesses compressed and the pad taut and to prevent lateral and longitudinal movement of the pad relative to the assembly and boxing, and

means `connecting the marginal edges of said cover sheet with the adjacent edges of said boxing.

6. The combination with aspring assembly of the kind described, of a cover sheet, a pad of compressible material positioned on the assembly under the cover sheet and initially having lateral and longitudinal dimensions greater than the corresponding dimensions of said assembly and cover sheet, the marginal edges of the pad being folded on top of the pad and underneath the cover sheet to provide a compressed double thickyness overlying the spring assembly, a border boxing comprising a plurality of connected plies ex tending around the edges of the spring assembly, a line of lacings extending diagonally through the double thickness of thepad and connecting its original edge portions with the adjacent edge of the spring assembly, said lacings being drawn taut and extending through the inner ply of said boxing for maintaining said double thicknesses compressed and the pad taut and to prevent lateral and longitudinal movement of the pad relative to the assembly and boxing, and means connecting the marginal edges of said cover sheet with the adjacent marginal edges of the outer plyv of the boxing.

MAX MARSACK. 

